Typical network architectures in manufacturing plants
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Advanced process control (APC) solutions such as MPC (model predictive control) have the ability to unlock vast amounts of hidden value by improving process stability and continuously optimising processing plants. MPC solutions make use of models derived from the actual process to predict future process behaviour from current and past data to ensure that the process is always operating optimally.
APC solutions optimise process KPI’s (key performance indicators) such as reducing emissions, increasing throughput, and improving conversion and typically have a payback period of 2 to 9 months. However, to ensure long-term value add and unlock the maximum return on investment, it is important to proactively manage the maintenance and monitoring of the implemented solutions.
The performance of advanced solutions may degrade over time due to the following factors:
These factors influence the process models and active constraints used in the advanced control solutions, which may lead to poor performance and reduced benefits if proper maintenance and monitoring are not performed.
The value add of an advanced control solution under various scenarios is shown below:
Knowing that your advanced solutions degrade over time is the first step. The next step is contacting an expert to:
We are happy to advise you on any tuning and APC projects. The right tooling can help you accomplish optimized plant performance.